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BFI OP. MANUAL 
PDF Version 



_ 



r 



A WARNING: BEFORE USING THIS FIREARM, 
READ AND FOLLOW THESE INSTRUCTIONS 

If there is anything you do not understand, 
get help from someone qualified in the safe handling of firearms. ® 




For all 



BUSHMASTER 
XM15 Models 



OPERATING AND SAFETY, 
INSTRUCTION MANUAL 



A1 & A2 Sight Systems 
All Rifles & Carbines 
including V Match 



PLEASE PRACTICE SAFE FIREARMS HANDLING! 

This instructional manual should always accompany your Bushmaster firearm. 



A 



WARNING: IF THIS FIREARM IS CARELESSLY OR IMPROPRERLY HANDLED, 
^"^UNINTENTIONAL DISCHARGE COULD RESULT AND COULD CAUSE INJURY, 

A DEATH, OR DAMAGE TO PROPERTY. 
CAUTION: CAREFULLY READ THIS INSTRUCTION MANUAL PRIOR TO LOADING 
AND FIRING THIS FIREARM. FOLLOW ALL INSTRUCTIONS ON THE PROPER 
HANDLING AND SAFE USE OF THIS FIREARM - LIVES MAY DEPEND ON IT! If 
unfamiliar with firearms, seek further advice through safe handling courses run by your 

A local gun clubs, NRA approved instructor, or similar qualified organizations. 
CAUTION: USE ONLY CLEAN, DRY, HIGH QUALITY COMMERCIALLY 
MANUFACTURED AMMUNITION IN GOOD CONDITION which is appropriate to the 
.223 Rem. caliber of your firearm. We do not recommend the use of reman ufactu red or 
hand loaded ammunition because it may damage your rifle. Use of improper ammunition 

A will invalidate your warranty. 
WARNING: THIS WEAPON COULD CHAMBER A ROUND if it is dropped or jarred with 
a loaded magazine in place - either with the Bolt Carrier Assembly locked to the rear, or in 
its forward position. 

PLEASE PRACTICE SAFE FIREARMS HANDLING! 



ALWAYS KEEP THE GUN POINTED IN A SAFE DIRECTION. 
NEVER LOAD THE GUN UNTIL READY TO USE. 
KEEP YOUR FINGER OFF THE TRIGGER UNTIL READY TO SHOOT. 



ZlA WARNING: BEWARE OF DANGEROUS PROCEDURES 

• Be sure cam pin is installed in the bolt group. If it isn't, your rifle can still fire and will 
explode. 

• If you are using a blank firing attachment, never fire anything except blank 
rounds (for safety, we recommend the visible military style blank firing attachment). 

• If your rifle stops firing with a live round in the chamber of a hot barrel (a misfire), 
remove the round fast. However, if you cannot remove it within 10 seconds, remove 
magazine and wait 1 5 minutes with the rifle pointing in a safe direction. This way you 
won't get hurt by a possible round "cooking-off" (i.e. the round detonating just from the 
heat of the barrel). In any event, keep your face away from the ejection port while 
clearing a hot chamber. 

• If your bolt fails to unlock, and you try to free it by banging the buttstock on the ground, 
keep yourself clear of the muzzle. 

• If there's water in the barrel, do not fire the rifle. It could explode. 

• If a noticeable difference in sound or recoil is experienced, STOP FIRING. Either 
condition could indicate an incomplete powder burn and/or a bullet stuck in the bore. 

ALWAYS PRACTICE SAFE FIREARMS HANDLING! 



FACTS ABOUT YOUR BUSHMASTER XM15 E2S RIFLE... 

The Bushmaster XM15 E2S rifle system consists of a rifle, a magazine, and a sling. It 
is a lightweight, gas operated, air-cooled, magazine-fed, shoulder-fired weapon that can 
be fired in a semi-automatic mode - i.e., a single shot each time the trigger is pulled. 

• The upper receiver and barrel assembly has a fully adjustable rear sight. 

• The upper and lower receivers are easily opened for cleaning and inspection. 

• The bolt group and barrel extension are designed with locking lugs that lock the bolt 
group to the barrel extension. 

• The forged aluminum upper and lower receivers reduce the weight of the rifle. 

• The bore and chamber are chrome plated for long life and ease of maintenance. 

• Caliber: .223 Remington / 5.56 mm 

• Weight: (depends upon model) 20" Bbl. Rifle = 8.27 lbs. / 3.75 kg 

• Length: (depends upon model) 20" Bbl. Rifle = 38.25" / 97cm 

• Barrel Rifling: R.H. twist; 1 in 9"; 6 lands & grooves 

• Firing characteristics: muzzle velocity approx. 3,260 fps; chamber pressure 52,000 psi 

• Maximum effective rate of fire: 45 rounds per min. / semi-automatic 

• Max effective range: 550 meters (individual/point targets) / 800 meters (area targets) 

• Maximum range: 3534 meters 
2 



TABLE OF CONTENTS 




Preventative Maintenance Checks 


29 






Safety Function Checks 


30 


Rifle Parts and Where To Find Them... 


. 4 


Adjustable Front Sight Post 


32 


Clearing Your Rifle 


6 


Dual Aperture Rear Sight.... 


32 


Disassembling Your Rifle 


8 


Zeroing Your Sights 


33 


Cleaning / Inspection / Lubrication 


13 


Zeroing Adjustments 


34 


Detailed Cleaning Techniques.... 


14 


25 Meter Zeroing Procedure 


34 


Cleaning the Upper Receiver.... 


15 


A1 Sights - Differences / Adjustments 


36 


Cleaning the Lower Receiver 


16 


Operation of Your Rifle / Loading. 


38 


Cleaning the Ejector 


17 


Operation / Inserting a Magazine... 


39 


Inspection before Lubrication 


18 


Operation / Chambering a Round... 


40 


Lubrication / Upper Receiver 


19 


Immediate Action in Case of Trouble 


42 


Lubrication / Lower Receiver 


19 


Remedial Action 


44 


Lubrication / Bolt Carrier Group.... 


20 


Bullet Stuck in the Bore. 


45 


Lubrication / Adjustable Rear Sight... 


21 


Troubleshooting 


46 


Reassembly 


22 


Parts Illustration 


54 


Magazine Disassembly / Reassembly 


28 


Limited Warranty 


55 



1\ WARNING: BEFORE USING THIS FIREARM, READ AND 
FOLLOW THESE INSTRUCTIONS. If there is anything you do 
not understand, get help from someone qualified in the safe 
handling of firearms. 



RIFLE PARTS AND WHERE TO FIND THEM (Right Side)... 

REAR SIGHT REAR SIGHT 




REAR SLING RELEASE (RIFLE ACCEPTS ALL 

LOOP BUTTON CAPACITY AR1 5 / M1 6 TYPE) 



RIFLE PARTS AND WHERE TO FIND THEM (Left Side) 

-A2 "SQUARE" FRONT 
SIGHT POST 
(A Round Post can be 
found on some A1 
models. Bushmaster 
only uses the A2) 




CARRYING HANDLE 
(A3 Removeable type is 
illustrated at lower left.) 



BUTTPLATE 
ASSEMBLY 
WITH "TRAPDOOR" 
STORAGE 
A2 TYPE 
UPPER RECEIVER 




Above, A Bushmaster 
V Match "Flat-Top" Style 
Upper Receiver And A3 Type 
Removeable Carry Handle. 
Right, an early A1 Upper Receiver 
(note the rear sight differences). 



CLEARING YOUR RIFLE... 




Place Safety Selector Lever on SAFE. 

(If the rifle is not cocked, the Selector 2 -> Press Magazine Catch Button and pull 
Lever cannot be pointed toward SAFE.) Magazine down to remove. 



CLEARING YOUR RIFLE (continued)... 



3.) To Lock Bolt Open, Pull Charging 
Handle rearward. Press bottom of 
Bolt Catch and allow Bolt to move 
forward until it engages Bolt Catch. 
Return Charging Handle to forward 
If you haven't before, place Safety 
Selector Lever on SAFE. 




4.) Check Receiver and 

Chamber to ensure there is 
no ammunition in the rifle. 



5.) With Selector Lever pointing 
toward SAFE, allow Bolt to 
go forward by pressing upper 
portion of Bolt Catch. 




DISASSEMBLING YOUR RIFLE... 




4.) Separate Upper and Lower Receivers. 5.) Pull back Charging Handle and Bolt Carrier 
8 



DISASSEMBLING YOUR RIFLE (continued)... 

DISASSEMBLE USING STEPS 13 THRU 16 ONLY WHEN DIRTY OR DAMAGED 

PUSH 




14.) Remove Extractor and Spring. 
CAUTION: Extractor Spring may 
pop out and get lost! 1 1 



DISASSEMBLING YOUR RIFLE 
(continued)... 

15.) Press in Buffer, depress Retainer, 
and release Buffer. 



16.) Remove Buffer and 
Action Spring. 




The Handguards may be disassembled at any point in your cleaning > 
procedures as necessary (see Pg. 27 - "Buddy System" instructions). 

If your Rifle is equipped with the A3 Type Removeable Carry Handle, BUSHMASTER 
that may be removed for cleaning by loosening the 2 thumbnuts. Clean as DOES NOT 

per instructions for aluminum Upper and Lower Receivers (see Pg. 16). RECOMMEND 

Lightly lubricate the thumbnut threads and the Rear Sight mechanism (as ANY FURTHER 

12 described on Pg. 21 - Lubrication - Adjustable Rear Sight). DISASSEMBLY 



CLEANING • INSPECTION • LUBRICATION... 

After firing, clean your rifle as soon as possible to make the job easier and to avoid allowing 
the development of any corrosion. 

When your firearm has not been fired, you should clean it at least once or twice a year if 
you live in a temperate climate, or as often as once a week in a tropical climate. 

If you get your firearm wet, clean it as soon as possible. 

Use a high quality rifle cleaning kit that includes a cleaning rod; swab holder; cotton flannel 
bore patches; pipe cleaners; a small toothbrush; brass wire bristle bore and chamber brushes 
and a Cleaner/Lubricant/Preservative (CLP in Army terminology). 

After you have disassembled the rifle, thoroughly clean, inspect and lubricate all parts 
according to the techniques described on following pages. 




DETAILED CLEANING TECHNIQUES... 

NOTE: The procedures below describe cleaning with a standard military 
issue multi-piece rod cleaning kit. Other commercial cleaning kits may 
include alternate cleaning instructions which may be just as effective. 

CLEANING THE BORE: The bore of your Bushmaster rifle has lands and 
grooves called rifling. Rifling makes the bullet spin very fast as it moves 
down the bore and down range. It is difficult to push a new, stiff bore brush 
through the bore. You will find it much easier, and more effective, to pull 
your bore brush through the bore. Also, because the brush will clean 
better if the bristles follow the grooves (this is called tracking), you want the 
bore brush to be allowed to turn as you pull it through. Always clean from 
from chamber toward the muzzle. This is how you do it: 

1 . ) Swab out the bore with a patch moistened with "CLP". 

2. ) Attach three rod sections together but leave each one about two turns 
short of being tight. 

3. ) Attach the bore brush but leave it two turns short also. 

4. ) Point muzzle down. Hold the upper receiver in one hand while inserting 
the end of the rod without the brush into the chamber. Guide the rod 
carefully through the bore. CAUTION - do not let the rod or its threaded 
end scratch the Chrome Lining of the Bore or Firing Chamber. 

About 2 - 3 inches of the rod should protrude out of the muzzle. 

14 




DETAILED CLEANING TECHNIQUES (continued)... 

5. ) Attach the handle section of the cleaning rod to the end of the rod sticking 
out of the muzzle. 

6. ) Pull the brush through the bore and out the muzzle. You should be able to 
see the rod twisting as you pull it - this is the brush "tracking" in the rifling. Never 
reverse the direction of the bore brush while it is in the bore. 

7. ) After one pull, take off the handle section and repeat the process. After 
three or four pulls, the three rod sections and the bore brush may become 
screwed tightly together. Loosen them up and repeat the process. 

8. ) Send a patch through the bore occasionally to help clean out the crud that 
the brush is getting loose. Just replace the bore brush with the rod tip (patch 
holder) and a wet patch. Pull it through. If you leave the rods loose again, the 
patch will "track" in the rifling as before. But remember, always have the bore 
wet with cleaner before trying to pull a brush through. 

CLEANING THE UPPER RECEIVER... 

NOTE: Check to ensure that there is no looseness between the Barrel 
and the Upper Receiver - if you detect any movement by twisting with your 
hands, the barrel nut must be retorqued. Bring the Rifle to a qualified 
gunsmith. ATTACH HANDLE 

1.) Using a "CLP" type product, clean all areas of Powder Fouling, AND PULL THROUGH 
Corrosion, Dirt and Rust. Never use a wire brush or any type of abrasive to FROM CHAMBER 
clean the Aluminum Upper Receiver - you'll scratch and damage the finish. TO MUZZLE 15 




CLEANING THE UPPER RECEIVER (continued)... 

2. ) Clean the Firing Chamber - dip the larger chamber cleaning brush in CLP and use at least 
five plunge strokes and three 360 clockwise rotations. Then swab out the bore as described 
previously to remove any contaminated solution or loosened crud. 

3. ) Use the bore cleaning brush, still wet with CLP, and clean carbon and powder residue from 
around the gas tube, run a pipe cleaner into the gas tube, clean the bolt locking lugs, bolt rings, 
firing pin, bolt cam pin, lip of the extractor, and inside the bolt carrier from both front and rear. 

4. ) Wipe all components clean and dry, and inspect A SMALL TOOTHBRUSH 
for excessive wear, corrosion or mechanical damage. i v WILL REMOVE BUILT-UP 
Replace any defective parts before firing again (call \ ^ s I D | RT 
us at 1 -800-998-SWAT for any parts needs.) 




CLEANING THE LOWER RECEIVER... 

1. ) Clean all areas of Powder Fouling, Corrosion, Dirt 
and Rust. Again, never use a wire brush or any type of 
abrasive to clean the Aluminum Lower Receiver. 

2. ) Wipe any dirt from the Trigger Mechanism. Clean J^J^^I^Jl^i^. I 
the Buffer, Action Spring, and inside 
the Lower Receiver Extension 
(the Buffer Tube). 

WIPE INSIDE OF BUFFER 
16 TUBE CLEAN 





THE BUTTPLATE SCREW 



PIPE 
CLEANER 



CLEANING THE EJECTOR... 

The design of the Ejector makes its disassembly for cleaning somewhat impractical (i.e. we 
don't recommend it). Make sure your Bushmaster ejects empty cases efficiently by following 
these steps on a monthly basis (more frequently if firing blanks). 

1. ) Remove the Bolt from the Carrier (as described on previous pages). Hold it as shown with 
the Ejector down and the Extractor up. 

2. ) Dribble a few drops of CLP around the Ejector to form a puddle. 

3. ) Take a fired or dummy case and place it under the lip of the Extractor. With a rocking motion, 
press the case down against the Ejector. Since the Ejector is spring loaded, some resistance will 
be felt. Press on the case until it stops against the bolt face. Ease off with your thumb slightly and 
press down again. Repeat several times. Replace the CLP frequently. Once the spring action 
of the Ejector is smooth and strong, dry off any excess. 

ROCK EMPTY CASE AGAINST 




INSPECTION - Before Lubricating. 




1.) Check the Bolt: Look for cracks or 
fractures, especially in the cam pin hole area. 
Bolts with pitting that extends into the firing 
pin hole should be replaced. 



2.) Check the Firing Pin: If it is bent, cracked, 
too blunted or too sharp, it should be replaced. 



3.) Check the Firing Pin Retaining Pin: If it is 
bent, or badly worn, it should be replaced. 




4.) Check the Cam Pin: If it is cracked, or 
chipped, it should be replaced. 

WARNING: IF THE CAM PIN IS MISSING, 
DO NOT FIRE THE RIFLE - IT WILL 
EXPLODE. 




5.) Check the Extractor and Extractor Spring: 
If the Extractor is chipped, or has broken 
edges in the area of the lip that engages the 
cartridge rim, it should be replaced. Check that 
the rubber insert is inside the Extractor Spring. 



18 



LUBRICATION - Upper Receiver.. 

Lightly lubricate the inside of upper receiver, the 
bore and chamber (using the cleaning rod and a 
patch), the outer surfaces of barrel and front sight, 
and surfaces under the handguard. Be sure you lube 
in and around all the Locking Lugs (see illustration at right). 

Depress the Front Sight Detent and apply two or three drops of 
CLP to it. Depress the detent several times to work the lubricant into 
the spring. 

LUBRICATION - Lower Receiver... 

Lightly lubricate inside the Lower Receiver Extension (Buffer 
Tube), the Buffer and the Action Spring. 

Generously lubricate all moving parts inside the Lower 

Receiver (trigger, hammer, safety, bolt catch, 

forward assist, etc), and their various pins 
and detents. Don't forget the 
Takedown and Pivot Pins and their 
detents. Wipe any fingerprints (they 
can start the corrosion process) off 
the exterior surfaces with an oiled 
rag - a black cloth is best as it won't 
leave visible lint. 





FRONT 
SIGHT 
DETENT 




19 



LUBRICATION - Bolt Carrier Group. 



Lightly lubricate the Firing Pin with CLP - also the Firing Pin 
recess in the Bolt. 

Generously lubricate the Bolt, its Cam Pin area, the Bolt Gas 
Rings. A lighter application is good on the Extractor and its Pin. 



Lightly lubricate the Charging Handle and the inner and outer 
surfaces of the Bolt Carrier. 

Generously lubricate the slide and Cam Pin area of the Bolt 
Carrier. 



The inside of the Carrier Key on the Bolt Carrier should be dried 
with a Pipe Cleaner - then place one drop of CLP inside. 



20 




LUBRICATION - Adjustable Rear Sight... 

Note: Record how far you move the rear sight so it can be returned to its original position upon 
the completion of this task. 

Rear Sight Moving Parts: Use 1 or 2 drops of CLP. Rotate these parts to ensure that the 
lubricant is spread evenly above, below and around the threads of the: 

1 . ) Elevation knob 

2. ) Elevation screw shaft 

3. ) Windage knob 

4. ) Windage screw 

5. ) Detent holes 

Elevation Screw Shaft: Also lube from inside 
the upper receiver as follows: 



WIN DAG 
KNOB^ 



1 . ) Turn upper receiver upside down 

2. ) Remove charging handle 

3. ) Put 2 or 3 drops on bottom of 
elevation screw shaft and in 
elevation detent spring hole 

4. ) Rotate the elevation dial back 
and forth a few times while 
keeping upper receiver upside- 
down 



WIN DAG 
SCREW 



BOTTOM OF 
ELEVATION 
SCREW SHAFT 
AND DETENT 
SPRING HOLE 



DETENT 
SPRING 
HOLE 




ELEVATION 
KNOB 



21 



REASSEMBLY. 






RUBBER 
INSERT 



Insert Extractor and Spring. 



1 .) Insert Action Spring and Buffer. Depress Buffer Detent, 
and push Buffer in past the Detent, then release. 

Note: Extractor Assembly has a Rubber Insert within the Spring. 
Be sure not to lose it. If the Spring comes loose, put the large end 
of the spring in the extractor and seat it (a bullet tip works well). 




22 



REASSEMBLY (continued)... stagger the gas ring gaps 

TO REDUCE GAS LOSS. Position the three 
ring gaps 120 apart around the bolt. 




23 



REASSEMBL Y (continued). . . 

WARNING: Be sure the Cam Pin is installed in the Bolt Group. If it isn't, your rifle can still fire 
and will explode! 

NOTE: The Bolt is machined so as to allow insertion of the Cam Pin from one side only. This 
provision aligns the Extractor and Ejector properly within the Upper Receiver. 



5.) Replace Bolt Cam Pin. 



24 





FIRING PIN 



6.) Drop in and seat 
the Firing Pin. 



GIVE 
CAM PIN 
A 1/4 TURN 
AFTER 
INSERTION 




7.) Pull Bolt out. 



REASSEMBL Y (continued). . . 

NOTE: Firing Pin should not fall out when 
Bolt Carrier Group is turned upside down. 





8.) Replace Firing Pin Retaining Pin. 



9.) Engage, then push Charging Handle part way. 




10.) Position Carrier Key in slotted bottom of 
Charging Handle. Slide in Bolt Carrier Group. 



CAUTION: Bushmaster does not recommend the practice of swapping bolts between 
different rifles. Doing so could result in damage, personal injury or death. 



25 




REASSEMBL Y (continued). 



14.) Close the Upper and Lower Receiver groups and push 
in the Takedown Pin. 



When re-attaching the Handguards, use 
The "Buddy System": 



15. ) Place the Rifle on the 

Buttstock and press down on 
the Slip Ring with both hands. 
Note: The "Half-Round" 
Handguards are identical and 
can be used on top or bottom. 

16. ) Have your buddy install one 

handguard on top and the 
other on the bottom. 





17.) Re-attach the Sling. 



27 



MAGAZINE DISASSEMBLY / REASSEMBLY ... 




Magazine Body, Spring, and Follower. Then 

lightly lubricate the Spring. REASSEMBLY is reverse of steps above. 

Make sure to slide the base under all four 



28 tabs until it snaps back under the catch. 



PREVENTATIVE MAINTENANCE CHECKS & SERVICES... 
CHECK BEFORE YOU FIRE! ... 

1 .) Check to see that there is no excessive oil in the Bore. If there is, swab it out with a patch and 
the cleaning rod. 




SAFETY FUNCTION CHECK. . . 
UNLOAD RIFLE - REMOVE MAGAZINE 



CHECK CHAMBER 



1. ) Remove magazine if installed. Pull Charging Handle assembly to rear. 
Check that Chamber is clear. Let Bolt and Bolt Carrier close. Do not pull 
Trigger. Leave Hammer in cocked position. 

WARNING: If Rifle fails any of the following tests, continued use of the 
Rifle could result in injury to, or death of, personnel. 

2. ) Place Selector Lever in SAFE position and pull Trigger. THE 
HAMMER SHOULD NOT FALL. 

3. ) Place Selector Lever in FIRE position. Pull trigger. THE HAMMER 
SHOULD FALL. 

NOTE: For the purpose of the following check, "SLOW" is defined as 
one fourth to one half the normal rate of trigger release. 

4. ) Hold Trigger to the rear, pull Charging Handle to the rear, and release 
pressure on the Trigger with a slow, smooth motion, without hesitations or 
stops, until the Trigger is fully forward. AN AUDIBLE CLICK SHOULD 
BE HEARD - THE HAMMER SHOULD NOT FALL. 

5. ) Repeat the FIRE position test five times. The Rifle must not 
malfunction during any of these five tests. If the Rifle malfunctions during 
any of these five tests, have the Rifle checked by a qualified gunsmith. 





30 



LOADING A MAGAZINE... 

1. ) Use only quality ammunition suitable for your firearm. 
Examine each cartridge - particularly around the primer. 
Look for dents, scratches, and other signs of damage. Do 
not load damaged ammunition. 

2. ) With the magazine facing forward as shown in the 
illustration, place a round between the lips of the magazine 
with the bullet tip forward. Push the round down until it is 
held by the magazine lips. 

3. ) If necessary, give the round a slight push backward to 
seat it against the back edge of the magazine lips. Place 
next round on top of previous round and repeat steps until desired number of rounds is loaded. 

CAUTION: Safe firearms handling dictates that you ONLY LOAD LIVE AMMUNITION INTO 
YOUR RIFLE WHEN YOU ARE ABOUT TO SHOOT. 

THE FORWARD ASSIST. . . 

The forward assist helps lock the bolt into the barrel, but it will only be useful on rare occasions 
when the bolt fails to lock automatically. If you find that you need to use the forward assist, it is 
probably time you cleaned your rifle - pay particular attention to the locking lug areas in the 
chamber and on the bolt. 

CAUTION: ALWAYS CHECK THAT AMMUNITION IS CLEAN AND UNDAMAGED BEFORE 
USING THE FORWARD ASSIST. Forcing dirty or damaged ammunition into the chamber could 
damage your rifle and could result in injury, death or property damage. «-| 




ADJUSTABLE FRONT SIGHT POST. . . 

The Front Sight Post is moved up and down when "Zeroing" the Rear Sight 
Once the Rear Sight is zeroed, the Front Sight Post should not be moved. 

A2 DUAL APERTURE REAR SIGHT... 

(See Page 36 forA1 Sight information) 




SHORT RANGE - This "larger" aperture is 
used for - 200 meters range. As shown 
above, the sight is set tor - 200 meters. This 
larger aperture is only used when the 8/3 
marking is aligned with the vertical mark on 
the left side of the upper receiver. 

32 




NORMAL RANGE - The smaller aperture is 
unmarked and is used for most firing 
situations. It is used in conjunction with the 
elevation knob for 300, 400, 500, 600, 700, 
and 800 meter targets. 



ZEROING YOUR SIGHTS... 

This is the procedure to follow in order to "Zero" your mechanical sights. 

1. ) In this procedure, the Front Sight Post and Rear Sight Windage Knob 
are adjusted so that you can hit your point of aim at 300 meters: 

2. ) Flip the unmarked (smaller) aperture to the up position (as shown). 

3. ). Set the Rear Sight so that the 300-meter mark is aligned with the mark 
on the left side of the receiver. 

ZEROING ADJUSTMENTS. . . 

1 . ) During zeroing procedures, only the front sight post and windage knob 
are adjusted to move the strike of the bullet on the target. 

2. ) If you are zeroing on a 25-meter range, the rear sight elevation knob is 
adjusted to the 300-meter mark plus one "click" up. 

3. ). Also see the detailed zeroing procedures on the following pages. 

FRONT SIGHT: To adjust elevation, depress detent and rotate 
post. To raise strike of bullet, rotate post in the direction of 
arrow marked UP. Reverse the direction of rotation to 
lower strike of bullet. Each graduation (notch) moves the 
point of impact of bullet as indicated. 

IMPACT DISTANCE 
0.9 cm (3/8 in.) 25 meters 
3.5 cm (1 3/8 in.) 1 00 meters 
7.0 cm (2 3/4 in.) 200 meters 




300 METERS 
ON THE 
ELEVATION KNOB 
(dial rotated down) 




ZEROING ADJUSTMENTS (continued) 



FOR WINDAGE KNOB (per click)* 
IMPACT DISTANCE 



WINDAGE KNOB 
POINTER 



0.3 cm (1/8 in.) 
1.25 cm (1/2 in.) 

2.50 cm (1 in.) 
3.8 cm (1 1/2 in.) 

5.0 cm (2 in.) 
6.3 cm (21/2 in.) 

7.6 cm (3 in.) 
8.8 cm (3 1/2 in.) 

10.0 cm (4 in.) 



25 meters 
100 meters 
200 meters 
300 meters 
400 meters 
500 meters 
600 meters 
700 meters 
800 meters 



WINDAGE 
SCALE 




*AII the above values have been rounded off. 
To remember your correct zero windage, note location of Windage Scale and Windage Knob 
Pointer (heavy mark on outside of knob). Once you have established your correct zero windage 
leave your Windage Scale and Windage Knob Pointer on these settings at all times. 

25 METER ZEROING PROCEDURES. . . 

Place an appropriate 25 Meter Paper Sighting Target 25 meters downrange and follow the 
steps below to establish a "battlesight" zero. 

1 . ) Do not move the front sight post on your Bushmaster XM15 E2S rifle at this time. It was set at 
the factory and should be very close to your zero. 

2. ) Center the rear sight aperture by turning the windage knob left or right. This is called 

"Mechanical Zero Windage". 
34 3.) The Unmarked (smaller) Aperture should be up. 



25 METER ZEROING PROCEDURES (continued)... 

4. ) Now rotate the elevation knob "up" one click past the 300-meter mark. From this point on, the 
elevation knob should not be moved. Any changes in elevation required in the following zeroing 
steps are made to the front sight post only. 

5. ) Carefully aim and fire at the center of the target bull's-eye. 

6. ) If your shot group is not in the center of the bull's-eye, use the squares on the target sheet to 
calculate the required "clicks" necessary to move your next shot group into the bull's-eye. 

Remember - any changes in elevation are made by moving front sight post only! 

7. ) In order to raise your next shot group, rotate the front sight post clockwise. One click of 
the front sight post will move the the bullet strike one vertical square on the target sheet. 

In order to lower your next shot group, rotate the front sight post counter-clockwise. One click 
of the front sight post, as above, equals one square. 

Changes in windage are made with the windage knob. Three clicks will move the strike of 
the bullet one horizontal square on the target sheet. 

In order to move the shot group to the left, turn the windage knob counterclockwise. 
In order to move the shot group to the right, turn the windage knob clockwise. 

8. ) Carefully aim and fire another group at the center of the target bull's-eye. 

9. ) Repeat Steps 7 through 9, if required. 

10. ) If your group is on target, your sight is now "calibrated." To place your actual 300-meter zero 
on the rifle, you must rotate the elevation knob one click "down." (The range scale's 300-meter 
mark should now be aligned with the mark on the rifle's receiver.) 



A1 TYPE RIFLE SIGHTS - DIFFERENCES & ADJUSTMENTS... 

A1 Type Rifles have sights that differ a bit from the later A2 Style. 

The A1 REAR SIGHT Has two apertures for differing ranges but does not offer any mechanical 
means of adjustment for elevation 

• Use the unmarked aperture for targets from - 300 meters. 

• Use the aperture marked L for targets from 300 - 400+ meters. 

The A1 FRONT SIGHT - Has five notches of elevation per revolution (instead of the four 
notches found on A2 square post type front sight - Bushmaster only uses the A2 type Front 
Sight Post in its current production models). 

EARLIER 
A1 ROUND 
SIGHT POST 



FIVE 

NOTCHES 

1 . ) Battlesight zero is that setting on the Rifle's sights which will cause the point of aim and 
strike of the bullet to be the same at 250 meters. 

2. ) When using the L-marked aperture, the path of the bullet will cross the line of sight at 25 
meters. Hence, zeroing is now conducted with point of aim and point of impact being the same 
(see chart on next page). 

36 




A1 SIGHTS - DIFFERENCES & ADJUSTMENTS (continued)... 

NOTE: To zero the rifle, adjust the front sight (elevation) and the rear sight (windage) so that you 
can hit the aiming point at a given range. 



LONG RANGE APERTURE 




FRONT SIGHT - To adjust elevation, depress detent and rotate post as 
described previously for A2 Front Sight Post. The 5 notches of the A1 post 
allow for a finer adjustment than does the square A2 Post with 4 notches. 
NOTE: Bushmaster uses only the newer A2 square front sight post. 
REAR SIGHT - To adjust windage, depress detent and rotate drum to , 
direction you want. Each notch moves the point of impact of bullet as jf7\ 
indicated in chart. I n 

1. ) To move point of impact to right, turn drum clockwise in direction 
of arrow and letter R. 

2. ) To move point of impact to left, turn drum counterclockwise 




IMPACT 

0.7cm (17/64 in.) 
2.8cm (1-3/32 in.) 
5.6cm (2-13/64 in.) 



DISTANCE 

25 meters 
1 00 meters 
200 meters 




OPERATION OF YOUR RIFLE... 

WARNING: If a noticeable difference in sound or recoil is experienced, STOP FIRING. 
Either condition could indicate an incomplete powder burn and/or a bullet stuck in the 
bore (Also see Page 45). Retract the bolt slowly and remove the fired cartridge case. 
Clear the weapon and check for unburned powder grains in the receiver or bore, and for 
a bullet stuck in the bore. Clean out any unburned powder before resuming firing. If a 
bullet is stuck in the bore, do not attempt to remove it. Take the rifle to a qualified 
gunsmith. 

LOADING... 

CAUTION: 

AL WA YS POINT THE MUZZLE 
IN A SAFE DIRECTION! 






38 



1 .) With Hammer cocked, 

place Selector Lever on SAFE. 




i Open Bolt and check Chamber. 
Make sure it is clear. 



OPERATION OF YOUR RIFLE... 
INSERTING A MAGAZINE... 




) Push Magazine up into Magazine Well 4.) Tap upward on Magazine bottom to 
until Magazine Catch engages and holds make sure it's seated correctly, 
the Magazine. 



39 



OPERATION OF YOUR RIFLE... 

CHAMBERING A ROUND with Bolt Assembly Open... 

NOTE: The Magazine may be inserted into the Rifle with Bolt Assembly open or closed. 

FORWARD ASSIST 




1 .) Depress upper portion of Bolt Catch. 2.) TAP the Forward Assist to ensure 

Bolt should spring forward. Bolt is fully forward and locked. 



OPERATION OF YOUR RIFLE... 

CHAMBERING A ROUND with Bolt Assembly Closed... 




NEVER "Ride" (or push) the Charging 3.)TAP the Forward Assist to ensure 

Handle. Let it move forward on its own. Bolt is fully forward and locked. 



NOTE: If the Rifle is not going to be fired immediately, make sure the Selector Lever 
is still on SAFE, and close the Ejection Port Cover to keep out dirt. 

41 



IMMEDIATE ACTION in case of trouble... 

IF YOUR RIFLE STOPS FIRING: Perform the following immediate actions. . . 

FIRING CHAMBER 




1 .) SLAP upward on Magazine to make 2.) PULL Charging Handle all the way back 

sure it's seated properly. Observe ejection of case or cartridge. 

Check Chamber for any obstruction. 

WARNING: DO NOT LOAD WITH A HOT CHAMBER. A ROUND MA Y ' COOK OFF" 
(meaning it may fire from the heat of the chamber) 



IMMEDIATE ACTION in case of trouble (continued)... 




REMEDIAL ACTION... 

WARNING: If your rifle stops firing with a live round in the chamber of a hot barrel, 
remove the round fast. However, if you cannot remove it within 10 seconds, remove the 
magazine and wait 15 minutes with the rifle pointing in a safe direction (always check that 
the "SAFE" direction remains safe during that time). This way you won't get hurt by a 
possible round cooking off. REGARDLESS, KEEP YOUR FACE AWAY FROM THE 
EJECTION PORT WHILE CLEARING A HOT CHAMBER. 




If your Rifle still fails to fire after performing If a cartridge case is in the chamber, open 
Steps 1 through 5 on previous page, check the receivers, remove the bolt carrier, and try 
again for a jammed cartridge case. t0 ta P out tne case witn a cleaning rod. 

IF YOUR RIFLE STILL FAILS TO FIRE, CHECK THE TROUBLESHOOTING SECTION 
44 IN THIS MANUAL - OR TAKE THE RIFLE TO A QUALIFIED GUNSMITH. 



BULLET STUCK IN THE BORE. . . 

WARNING: If an audible "POP" or reduced RECOIL is experienced during firing, 
immediately CEASE FIRE: Then, (1) Remove the Magazine, (2) Lock the Bolt to the rear, 
(3) Place the Selector Lever on the SAFE position and (4) visually inspect and/or insert a 
cleaning rod into the bore to ensure there is not a bullet stuck in the bore. 



4. Check for a 




DO NOT APPLY THE "IMMEDIATE ACTIONS" PREVIOUSLY DESCRIBED ON PAGE 43. 



IF A BULLET IS STUCK IN THE BARREL OF THE WEAPON, DO NOT TRY TO REMOVE IT. 
TAKE THE RIFLE TO A QUALIFIED GUNSMITH. 

45 



TROUBLESHOOTING. . . 




PROBLEM 


CHECK FOR: 


WHAT TO DO 


WONT FIRE 


Selector Lever on SAFE 


Put it on FIRE 




Improper assembly of 
Firing Pin. 


Assemble correctly. 

RETAINING PIN GOES IN BACK OF LARGE 




Too much oil in Firing 
Pin recess. 


SH0U LD ^^^^^^^^^^^^^^ 
Wipe out with pipe cleaner, ^t^* 




Defective Ammunition 




46 


Too much carbon on 
Firing Pin or in Firing Pin 
recess. 


Remove and dis^^^^^^^^^^ 



TROUBLESHOOTING (continued).. 

PROBLEM CHECK FOR: 


WHAT TO DO 








BOLT WONT Dirty or burred Bolt. 
UNLOCK 


Clean or see a qualified gunsmith. 


f 




WONT EXTRACT Broken Extractor Spring. 


See a qualified gunsmith. 






Dirty or corroded Ammo. 


Remove stuck round - push out 
with cleaning rod. 








Carbon in Chamber. 


Clean Chamber. 








Fouling or carbon in 
Extractor recess or lip. 


Clean Extractor. Jr&^^ 


^6ft 




47 



TROUBLESHOOTING (continued)... 

PROBLEM CHECK FOR: WHAT TO DO 



WONT FEED Dirty or corroded Ammo. Clean. 

Dirty Magazine. Clean. 

Defective Magazine. Replace. 

Too many rounds in Take out excess. 
Magazine. 

Action of Buffer Take out Buffer and Spring - Clean them. 
Assembly is restricted. 

Magazine not fully Adjust Magazine Catch: 



48 




TROUBLESHOOTING (continued)... 

PROBLEM CHECK FOR What To Do 



WONT FEED 
(continued) 



Turn Catch Clockwise to tighten and 
Counterclockwise to loosen 



TURN CATCH 
ON LEFTSIDE 




DOUBLE FEED 



Defective Magazine. 



Replace. 



WONT CHAMBER Dirty or corroded Ammo. Clean. 

Damaged Ammo. Replace. 

Carbon in Chamber or Clean, 
on Gas Tube 




TROUBLESHOOTING (continued)... 

PROBLEM CHECK FOR: WHAT TO DO 



WONT LOCK 



Dirt, corrosion, or carbon Clean lugs 
buildup in barrel locking 
lugs 




WONT EXTRACT Frozen Extractor. 

Restricted Buffer 
Assembly. 



Remove and 
clean. 

Remove and 
clean. 



CLEAN 




50 



Restricted movement of Remove, clean, and lube. 
Bolt Carrier Group. (Before putting Bolt back in, make sure Gas 

Tube fits into Carrier Key and that the Carrier 

moves freely.) 



TROUBLESHOOTING (continued)... 

PROBLEM CHECK FOR What To Do 



SHORT RECOIL 



Correct alignment of 
Gaps in Bolt Gas Rings 



"Gaps" in the 3 Gas Rings should be 
staggered 120 around the Bolt body for 
maximum effectivness. 



GAP 



GAP 




GAP 



Carbon or dirt in Carrier Clean Carrier Key or around area of the Gas 
Key or on outside of Gas Tube. 
Tube. 




51 



TROUBLESHOOTING (continued)... 

PROBLEM CHECK FOR: WHAT TO DO 



SHORT RECOIL 
(continued) 



BOLT FAILS TO 
LOCK AFTER 
LAST ROUND 



SELECTOR 
LEVER BINDS 



Q-Tip or Pipe Cleaner 
pieces stuck inside 
Carrier Key. 



Clean out if possible or have Rifle checked by 
a qualified gunsmith. 




52 



Dirty or corroded Bolt 
Latch. 



Faulty Magazine 

Needs oil. 

Dirt or sand under 
Trigger. 



Clean - or replace Bolt Catch. 
Check for Buffer Endcap backout or 
obstruction. 

Check for full travel of Bolt Carrier 
Replace. 

Lubricate with CLP. 
Clean. 



TROUBLESHOOTING (continued)... 

PROBLEM CHECK FOR: WHAT TO DO 



BOLT CARRIER 
"HUNG UP" 



Round jammed between 1 ■) Remove Magazine. 




Bolt and Charging 
Handle and/or double 
feed 



WARNING: 
KEEP CLEAR 
OF MUZZLE. 



2. ) Push in on the bottom of the Bolt Latch. 

3. ) While pulling down on Charging Handle, 
bang the Rifle Butt on the ground. Bolt should 
lock to the rear. 

4. ) While Bolt is held to the rear, round should 
fall through the Magazine well. 




CAUTION: 
AFTER ROUND 
IS REMOVED, 
BOLT IS UNDER 
TENSION 



NOTE: If this procedure fails, use a section of cleaning rod to 
push the Bolt fully to rear through the Ejection Port. 



53 





PLEASE PRACTICE SAFE FIREARMS HANDLING 

If your Bushmaster Operation Manual is lost or destroyed, you can obtain a 
replacement by writing to Bushmaster Firearms, Inc. 999 Roosevelt Trail, Windham, 
Maine 04062 USA or by calling 1-800-883-6229. When requesting a manual, include 
the serial number of your rifle. 

This Operation Manual should always accompany this firearm. When you lend, give or 
sell this firearm, be sure this Manual goes with it. 



Model: 



Serial Number: _ 
Purchased from: 
Date Purchased: 

56 



PLEASE PRACTICE SAFE FIREARMS HANDLING! 

LIMITED ONE-YEAR WARRANTY Bushmaster Firearms Inc. products are warranteed to be free from 
defects in material and workmanship. Warranty cards are included with all firearms and should be completely 
filled out and sent to Quality Parts Company to activate the terms of the warranty. Any such defect of which 
Bushmaster Firearms Inc. is given written notice, as provided below, within one year and ten days from the 
date of first purchase by a customer will be remedied by Bushmaster Firearms Inc. without notice. This 
warranty is granted by Bushmaster Firearms Inc., 999 Roosevelt Trail, Windham, ME 04062. Warranty claims 
(in writing) and the firearm concerned should be directed (transportation charges prepaid), to the Warranty 
Service Department, Bushmaster Firearms Inc., 999 Roosevelt Trail, Windham, ME 04062. 

Warranty claims should state the model and serial number of the gun concerned, a description of the 
difficulty experienced, and the date of purchase. It is recommended that shipment be insured by owner, since 
Bushmaster Firearms, Inc. will accept no responsibility for loss or damage in transit. Transportation and 
insurance charges for return to owner will be paid by Bushmaster Firearms Inc. if the related claim is a proper 
claim for warranty work. 

A SAFETY NOTE REGARDING LEAD... Discharging firearms in poorly 
ventilated areas, cleaning firearms, or handling ammunition may result in 
exposure to lead, a substance known to cause birth defects, reproductive 
harm, and other serious physical injury. Have adequate ventilation at all 
times. Wash hands thoroughly after exposure. 

call 1 -800-998-SWAT for all 

REPLACEMENT PARTS AND ACCESSORIES 

BUSHMASTER FIREARMS, INC. / QUALITY PARTS CO.V^JEKLITY 

999 Roosevelt Trail P.O. Box 1479 Windham, Maine 04062 U.S.A. PAI£BS N CO. 
CUSTOMER SERVICE: 1 -800-883-6229 / Fax: 207-892-8068 
Website: http://www.bushmaster.com E-mail: info@bushmaster.com 



PLEASE PRACTICE SAFE FIREARMS HANDLING! 



always Keep the gun pointed in a safe direction. 
never load the gun until ready to use, 
keep your finger ol : the trigger until ready to shoot. 






IN THE U.S.A. 



BUSHMASTER FIREARMS, INC. / QUALITY PARTS CO. 

999 Roosevelt Trail • P.O. Box 1479 • Windham, Maine 04062 • U.S.A. 
ORDERS: 1 -800-998-SWAT • CUSTOMER SERVICE: 1-800-883-6229 
Website: http://www.bushmaster.com • E-mail: customerservice@bushmaster.com 



©1999 Bushmaster Firearms, Inc.